 Heater Core that fits in the fresh air box with minimal trimming! |
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| captain awesome |
 Dec 8 2025, 12:07 PM
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#1
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Newbie  Group: Members Posts: 38 Joined: 4-July 24 From: Bella Vista, AR Member No.: 28,217 Region Association: None  |
So I originally planned to use a Ford heater core but kept thinking there has to be something that will fit without requiring a "bump out" of the lid. Turns out a Honda s2000 fit great!
I trimmed the inner lip flush. The upper rain cover needed maybe a 1/2" removed to get it all to sandwich together. The outlets swivel with an internal o-ring so you can adjust the direction or placement of the hoses. Attached thumbnail(s)   
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| captain awesome |
Dec 8 2025, 12:08 PM
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#2
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Newbie Group: Members Posts: 38 Joined: 4-July 24 From: Bella Vista, AR Member No.: 28,217 Region Association: None |
More pics
Attached thumbnail(s)   
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| Ninja |
Dec 8 2025, 02:12 PM
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#3
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Newbie Group: Members Posts: 42 Joined: 25-September 25 From: Granbury Texas Member No.: 29,004 Region Association: Southwest Region |
Thanks for posting!
That does fit pretty nice! |
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| bdstone914 |
Dec 9 2025, 04:48 AM
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#4
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bdstone914 Group: Members Posts: 5,211 Joined: 8-November 03 From: Riverside CA Member No.: 1,319 |
It will be interesting to see if the fresh air box can take the heat. I once put a housing in the ultra sonic and heated the water to 180 degrees F. The box looked like a Salvadore Dali clock.
The other concern is the weight you are adding. Most air boxes have cracks at the two mounting points at the top. I have added two more mounting holes and nuts as the flanges have the holes already. |
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| captain awesome |
Dec 9 2025, 08:31 AM
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#5
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Newbie Group: Members Posts: 38 Joined: 4-July 24 From: Bella Vista, AR Member No.: 28,217 Region Association: None |
QUOTE(bdstone914 @ Dec 9 2025, 04:48 AM)  It will be interesting to see if the fresh air box can take the heat. I once put a housing in the ultra sonic and heated the water to 180 degrees F. The box looked like a Salvadore Dali clock. The other concern is the weight you are adding. Most air boxes have cracks at the two mounting points at the top. I have added two more mounting holes and nuts as the flanges have the holes already. There are plenty of examples of others using heater cores in the stock fresh air box, so I don't think there's any real concern of it melting. It's also a smaller core than most have used so it seems less likely to crack than most. I will however keep an eye on that, possibly reinforce the mounting area to ensure it lasts longer than a few trips. |
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| bdstone914 |
Dec 9 2025, 10:05 AM
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#6
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bdstone914 Group: Members Posts: 5,211 Joined: 8-November 03 From: Riverside CA Member No.: 1,319 |
QUOTE(captain awesome @ Dec 9 2025, 08:31 AM) QUOTE(bdstone914 @ Dec 9 2025, 04:48 AM) It will be interesting to see if the fresh air box can take the heat. I once put a housing in the ultra sonic and heated the water to 180 degrees F. The box looked like a Salvadore Dali clock. The other concern is the weight you are adding. Most air boxes have cracks at the two mounting points at the top. I have added two more mounting holes and nuts as the flanges have the holes already. There are plenty of examples of others using heater cores in the stock fresh air box, so I don't think there's any real concern of it melting. It's also a smaller core than most have used so it seems less likely to crack than most. I will however keep an eye on that, possibly reinforce the mounting area to ensure it lasts longer than a few trips. It is the plastic on the housing that cracks as the assembly is only supported at two points and the fan is an under hung weight that stresses the mounting points. I know others have mounted heater cores in blower boxes. Hope it works for you. I don't know why the blower box melted. Maybe a combination of heat and ultra sonic vibration. I have a Subi conversion and have thought about adding heat. But not much is needed in California |
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